Magnetic construction system and method

ABSTRACT

A magnetic construction system comprised of plural multi-shaped structural bodies each containing one or more captured magnets, wherein each magnet is free to rotate within its respective retaining pocket to align in magnetic polarity with rotatable magnets in adjacent structural bodies. Surface geometry around each magnet may include a radial detent feature which provides lateral and rotational stability between magnetically coupled structural bodies, or a radial recess which allows free rotation of respective structural bodies about the polar axis of magnetic coupling.

CROSS REFERENCE TO RELATED APPLICATIONS

This Application is a Continuation of application Ser. No. 14/169,094filed on Jan. 30, 2014, now U.S. Pat. No. 10,173,143; with applicationSer. No. 14/169,094 claiming the benefit of U.S. Provisional Application61/759,189 filed on Jan. 31, 2013; the contents of these applicationsare hereby expressly incorporated by reference in their entireties forall purposes.

FIELD OF THE INVENTION

This invention relates generally to magnetic construction systems, andmore specifically, but not exclusively, to magnetic construction systemsusing permanent dipole magnets rotatably retained within correspondingpockets in multiple structural bodies which may attract, one to another,via the ability of the respective magnets to rotate as needed for properorientation and alignment of opposite magnetic poles.

BACKGROUND OF THE INVENTION

The subject matter discussed in the background section should not beassumed to be prior art merely as a result of its mention in thebackground section. Similarly, a problem mentioned in the backgroundsection or associated with the subject matter of the background sectionshould not be assumed to have been previously recognized in the priorart. The subject matter in the background section merely representsdifferent approaches, which in and of themselves may also be inventions.

Numerous systems have been designed to allow for repeated constructionand deconstruction of structures. Such arrangements generally allow avariety of different parts to work together as a unified system withcommon attachment geometries or methods allowing individual parts to bereconfigured to create new forms. One common part interlock method usedis that of an interference fit, also known as a press-fit. Despite thebuilding flexibilities provided by press-fit attachment methods, thereare also some common drawbacks, such as difficulty of assembly, andlater disassembly, especially by younger children, and generally theinability to remove an internal part without first removing partsattached thereupon.

Magnetic construction inter-connects can facilitate the process ofconnecting parts into structures, through natural magnet attraction, aswell as the process of detaching parts, even allowing internal, boundedparts to be slid out and replaced. Magnetic construction systems varysignificantly in terms of how this magnetic coupling is achieved. Somesystems may employ permanent dipole magnets fixed within a structuralbody with magnet polarity oriented perpendicular to the body surface. Asa result, attaching two or more parts requires proper orientation ofstructural bodies such that magnetic polarities are aligned. However,this fixed dipole arrangement means a user has a 50% chance of needingto flip any given piece prior to attachment. For multilayer systems, itmay difficult, if possible, to flip a connecting part, especially partshaving multiple magnets which all must have a proper predeterminedorientation. For parts that are not manufactured in a specific way withspecific magnetic orientations, some construction options are excluded.

Other magnetic construction systems may address this polarity alignmentissue by adding an intermediate ferromagnetic piece which can attachequally well to either the north or the south pole of any dipole magnet.However, the need for a separate ferromagnetic part impacts systemarchitecture, ease of construction, safety, and overall cost.

Similarly, some magnetic construction systems may employ loose magnetsto attach structural bodies at ferrous attachment points. However, thisapproach has corresponding shortcomings, and brings up the additionalsafety concerns associated with the risk of children ingesting two ormore loose magnets and having them internally magnetically couple.

A fourth approach could involve a use of captive magnets which are freeto rotate within structural bodies, allowing self-alignment of theirmagnetic polarities when the magnetic fields of adjacent magnetssufficiently overlap, such as when parts are adjacently positioned formagnetic coupling. Some systems could employ cylindrical permanentdipole magnets positioned proximate to linear perimeter edge surfaces ofgeometric forms, such that the geometric axis of each cylindrical magnetis parallel with an adjacent linear perimeter edge surface, and thepolar axis is perpendicular to the geometric axis. Clearance betweeneach magnet and corresponding magnet retaining pocket within thestructural body may allow each magnet to swivel freely about itscylindrical axis, allowing the polar axis of any magnet to align withthe polar axis of any magnet in an adjacent part. Accordingly, adjacentparts may be able to magnetically couple along their linear perimetersurface segments and to pivot with respect to the linear contact betweensaid perimeter surface segments. This architecture may remove any needto actively orient parts to align magnetic polarity for part coupling.However, one notable result of this architecture in which the rotationaxis of the cylindrical magnet is perpendicular to the polar magneticaxis is that two magnetically attached parts find magnetically stableattraction at increments of each 180 degrees; when one part is twistedabout the magnetic axis of attachment, the magnets provide rotationalresistance (by virtue of the magnetic fields attracting the magnets to aposition of parallel cylinders) until the associated magnet has beenrotated past 90 degrees, at which point the respective magnetic fieldsthen attract the magnets to the next stable orientation of parallel axesof the cylinders, 180 degrees from the last stable position. Thisbi-stable coupling behavior may be considered desirable in one respect,by helping part edges to align along their linear edge geometry, but italso means that this magnet architecture it not suitable forapplications in which smooth and continuous rotation is desirable, suchas with magnetically attached wheels, gears, or chain segments.Furthermore, the combined thickness of two intermediate part wallsbetween coupled magnets reduces magnetic coupling force significantly,therefore requiring larger or stronger magnets for any desiredconnection strength and commensurately increasing overall system cost.

Some systems may make use of an internally captured spherical dipolemagnet which is free to swivel within a retaining pocket to match thepolarity of a like magnet in an adjacent piece. Two such magneticallycoupled parts could rotate with respect to one another but mayexperience considerable rotational friction between contact surfaces dueto the local clamping load applied by the respective magnets. Again,this could be a shortcoming for applications where low-friction,smooth/continuous rotational movement is desired, such as with wheel orgear axles, and wall thickness would meanwhile detract from magneticcoupling force. Furthermore, such a magnetic coupling may not providesufficient rotational stability to allow for stable structures,especially when the magnetic coupling axis is oriented horizontally andthe weight of attached parts may cause unwanted rotation orbending/sagging of parts about said axis.

Other systems may employ an alternate mechanisms to achieve a similareffect. In one architecture, cylindrical magnets may be orientated withthe geometric axis of each magnet perpendicular to the adjacent bodysurface, and the polar axis of the magnet perpendicular to the geometricaxis. Each magnet could freely swivel only about its cylindrical axis,such that the polar axis remains parallel with the respective bodysurface. If two or more such parts are positioned for magnetic coupling,the respective magnets may self-orient with parallel and opposedpolarities. Parts may rotate with respect to one another about thismagnetic coupling, via the capability of either magnet to rotate withinits retaining pocket, but the interposing surfaces may experiencesignificant friction due to the clamping force exerted by the magnets,thereby resisting rotation, while the wall thickness of the retainingwalls detracts from the coupling force of the magnets.

Still other systems may include a rather complex pivotable subassemblycomprised of a disc shaped magnet with a polarity coaxial with itsgeometric axis, and a pivotable carrier which allows the magnet toaxially rotate perpendicular to the polar axis so that either magneticpole may face outward. Two of the magnetic subassemblies may therebyrespectively swivel to magnetically align, enabling attachment ofcorresponding structural bodies. This magnetic coupling may allowrelative rotation of either structural body about the shared magneticaxis when an applied rotational force overcomes related friction betweencontact surfaces. However, this system has no provision for providingrotational stability between coupled structural bodies when so desired,and requires multiple additional parts for the subassembly required ineach magnet location.

A further variation may provide that each of the relatively complexpivotable magnet holder subassemblies has built-in circumferential teethwhich index with like teeth in other pivotable subassemblies. In thisarrangement, relative rotation of magnetically coupled parts is alwaysachieved in an indexed fashion, and is not capable of free rotation whenso desired. As before, the part count and complexity of each pivotablemagnetic subassembly translates to increased overall cost.

In summary, various magnetic construction systems may employ differentmechanisms and methods of aligning magnetic polarity between parts, butnot in a manner which comprehensively enables self-alignment of magnetsvia geometric rotation while also enabling any magnetic coupling toserve either as a freely rotatable, low-friction axis of rotation whendesired (such as for wheels, gears, or chains links), or as arotationally stable connection point with indexed rotation detentssuitable for structural stability. Therefore, to provide the greatestutility in further expanding construction capabilities, what is neededis a magnetic construction system with self-aligning, exposed magnetsand a capability to allow either free or indexed rotation betweenmagnetically coupled parts.

BRIEF SUMMARY OF THE INVENTION

Disclosed is a magnetic construction system and method includingstructural bodies capturing partially-exposed, rotatable andself-aligning magnets.

The following summary of the invention is provided to facilitate anunderstanding of some of the technical features related to theconstruction and the mechanical and magnetic behavior of the system, butis not intended to be a full description of the present invention. Afull appreciation of the various aspects of the invention can be gainedby taking the entire specification, claims, drawings, and abstract as awhole. The present invention is applicable to devices and methods otherthan magnetic construction systems as well as to other magnetic tools,coupling systems, and mechanisms.

Embodiments of the present invention include structural bodies andpermanent dipole magnets. Each structural body is constructed of two ormore permanently attached structural parts which together form one ormore pockets, and each pocket has two equal and opposed outward-facingopenings of restricted aperture. These pockets serve to capture acorresponding number of permanent magnets which are free to rotate tomagnetically align with magnets in adjacently positioned structuralbodies. The outward facing surface of each magnet is partially exposedthrough the openings with the exposed portions able to contact or tocome within close proximity with a like exposed surface of othermagnets, thereby increasing magnetic coupling force. Two or moremagnetically coupled structural bodies are able to rotate with respectto one another about the axis of magnetic coupling in either an indexedand clicking manner via detents, or alternatively in an arrangementallowing free and smooth rotation between respective parts.

In one implementation, an underlying geometry of each structural body isbased on an extended pattern of efficiently nested, equal-sizedequilateral triangles, wherein: a) each triangle apex is coincident withthe apex of five other like triangles; b) every side of every triangleis coincident with one side of an adjacent triangle; c) any adjacentapex of any triangle, separated by a single triangle side length,represents a possible magnet position within the structural body; d) theperimeter geometry of the structural body surrounding any such magnetposition (hereafter ‘magnetic node’ or ‘node’) is comprised of one ormore radial arcs with said possible magnet locations as center points,with all such radii substantially equal in dimension and substantiallyequating to half the length of a side of the equilateral triangle.Magnetically coupled nodes therefore share the same underlyingequilateral pattern, promoting the ability to efficiently stack or neststructural bodies in a manner consistent with the underlying pattern.Stacking includes the use of multiple overlapping or overlaying planes,each plane conforming to the underlying geometry of the extended patternwith magnet locations aligned across planes. In addition, the geometryof specific parts allows out-of-plane constructions in which two or moreplanes of the extended pattern may intersect.

With magnets thus positioned centrally within one or more nodes of eachstructural body, two or more magnetically coupled structural bodiescreate a shared magnetic axis running through the center of eachmagnetically coupled node. Any such magnetic axis may serve as an axisabout which said structural bodies may rotate in relation to oneanother.

Furthermore, around the geometric axis extending through opposing magnetpocket openings, the surface of the structural body may be characterizedby alternating and axially repeating protrusions and recessed featuresserving together as detents, such that: 1) two like surfaces of anynodes may nest one into the other in a rotationally stable manner whensaid nodes are magnetically coupled, and; 2) said nodes may beintentionally rotated with respect to one another without magneticdecoupling; and 3) said rotation may be characterized by discreetrotational clicks provided by said detents. Alternately, in specificstructural bodies the geometry around said geometric axis may instead becharacterized as a revolved, sunken surface which does not engage withthe described detent protrusions of other parts, thereby allowing freerotation without discreet detent clicks.

An embodiment of the present invention includes an apparatus, having ahousing providing a plurality of magnetic coupling nodes, the said nodedefined at a vertex of an equilateral triangular node pattern, saidhousing having a first face defining a first mating surface centered atthe said node, the said first mating surface substantially similar tothe other, said housing further including a perimeter wherein a portionof said perimeter proximate the said node includes a node perimetercontour and a portion of said perimeter intermediate a pair of adjacentnodes includes a body perimeter contour different from said nodeperimeter contour, said body perimeter contour complementary to saidnode perimeter contour wherein said node perimeter contour nests intosaid body perimeter contour, said housing further defining a pluralityof internal cavities, one internal cavity associated with the said nodeof said plurality of nodes; and a plurality of permanent dipole magnets,one permanent dipole magnet disposed in the said internal cavity whereinsaid one permanent dipole magnet disposed in a particular cavity isproximate said first mating surface centered on said node associatedwith said particular cavity.

Another embodiment of the present invention includes a constructingmethod including a) positioning a first magnetic constructing device ofa set of magnetic constructing devices at a first location, theconstructing device of said set of magnetic constructing devicesincluding a housing providing a plurality of magnetic coupling nodes,the said node defined at a vertex of an equilateral triangular nodepattern, said housing having a first face defining a first matingsurface centered at the said node, the said first mating surfacesubstantially similar to the other, said housing further including aperimeter wherein a portion of said perimeter proximate the said nodeincludes a node perimeter contour and a portion of said perimeterintermediate a pair of adjacent nodes includes a body perimeter contourdifferent from said node perimeter contour, said body perimeter contourcomplementary to said node perimeter contour wherein said node perimetercontour nests into said body perimeter contour, said housing furtherdefining a plurality of internal cavities, one internal cavityassociated with the said node of said plurality of nodes; and aplurality of permanent dipole magnets, one permanent dipole magnetdisposed in the said internal cavity with the permanent dipole magnetincluding a north magnetic pole and a south magnetic pole and with saidone permanent dipole magnet disposed in a particular cavity proximatesaid first mating surface centered on said node associated with saidparticular cavity; b) positioning a second magnetic constructing deviceof said set of magnetic constructing devices at said first location withone or more first particular mating surfaces of said first magneticconstructing device proximate to one or more second particular matingsurfaces of said second magnetic constructing device; c) rotating saidmagnets at nodes associated with said particular mating surfaces so anorth pole of a first magnet is aligned with a south pole of a secondmagnet producing one or more magnetic coupling forces; and d) retainingsaid second magnetic constructing device to said first magneticconstructing device using said one or more magnetic coupling forces.

In at least one embodiment of the present invention, the magnet isspherical in form, and the retaining pocket is accordingly dimensionedto allow said magnet to freely rotate about any axis extending throughthe center point of said magnet.

Other features, benefits, and advantages of the present invention willbe apparent upon a review of the present disclosure, including thespecification, drawings, and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying figures, in which like reference numerals refer toidentical or functionally similar elements throughout the separate viewsand which are incorporated in and from a part specification, furtherillustrate the present invention and, together with the detaileddescription of the invention, serve to explain the principles of thepresent invention.

FIG. 1 illustrates an exploded view of one structural body embodimentwith four magnetic nodes.

FIG. 2 illustrates the permanently assembled state of the structuralbody shown in

FIG. 1.

FIG. 3 illustrates a top view of the structural body of FIG. 2.

FIG. 4 illustrates a cross section view of the structural body of FIG.3, taken through line A-A in FIG. 3.

FIG. 5 illustrates a detail view of the cross section of FIG. 4, showinga magnet rotatably captured within a corresponding retaining pocket inthe structural body.

FIG. 6 illustrates the cross section detail view of FIG. 5, with anadditional structural body moving into a state of magnetic coupling,causing rotation of both magnets to achieve alignment of their magneticpolarities.

FIG. 7 illustrates the cross section detail view of FIG. 6 with the twostructural bodies in a magnetically coupled state.

FIG. 8 illustrates the equilateral triangle pattern basis underlyingstructural body geometry.

FIG. 9 illustrates several structural bodies in a laterally nestedconfiguration according to the underlying pattern of FIG. 8.

FIGS. 10-20 illustrate embodiments of substantially flat structural bodygeometries.

FIGS. 21-22 illustrate a structural body with one magnetic nodesubstantially perpendicular to another.

FIG. 23 illustrates a structural body with a hinge feature betweenmagnetic nodes.

FIG. 24 illustrates two magnetic nodes flexibly attached by anelastomeric interconnecting member.

FIG. 25 illustrates a top view of the structural body of FIG. 10, withsection line C-C intersecting peak amplitude in the undulating surfaceof the structural body.

FIG. 26 illustrates a cross section detail view of the structural bodyof FIG. 25, taken through line C-C in FIG. 25.

FIG. 27 illustrates a top view of an alternate structural bodyembodiment with a sunken surface around each magnetic node.

FIG. 28 illustrates a cross section detail view of the structural bodyof FIG. 27, taken through line D-D in FIG. 27.

FIG. 29 illustrates one side of an alternate structural body embodimentwhich incorporates the sunken surface of FIGS. 27-28, providing afree-spinning wheel which uses the axis of magnetic coupling as the axisof rotation.

FIG. 30 illustrates the other side of the structural embodiment of FIG.29.

FIG. 31 illustrates an example construction made from various structuralbodies according to the present invention.

FIG. 32 illustrates an exploded view of an alternate embodiment in whichspherical magnets are captured via separate retention rings.

FIG. 33 illustrates a collapsed view of the embodiment of FIG. 32.

FIG. 34 illustrates a top view of the embodiment of FIG. 33.

FIG. 35 illustrates a cross section view of the embodiment of FIG. 34taken through line E-E of FIG. 34.

FIG. 36 illustrates an exploded view of an alternate embodiment in whichmagnets are contained within pockets on multiple faces of a structuralbody, and each magnet is exposed on only one face.

FIG. 37 illustrates a collapsed view of the embodiment of FIG. 36.

FIG. 38 illustrates a top view of the embodiment of FIG. 37.

FIG. 39 illustrates a cross section view of the embodiment of FIG. 38,taken through line F-F of FIG. 38.

FIG. 40 illustrates a cross section detail view of an alternateembodiment in which a rotatably retained magnet is fully encapsulated byan associated structural body.

FIG. 41 illustrates an exploded view of an alternate embodiment in whicheach magnet is pivotally constrained within a retaining pocket.

FIG. 42 illustrates a detail view of the embodiment of FIG. 41, showingthe magnet polarity perpendicular to the geometric axis of rotation.

FIG. 43 illustrates an assembled state of the embodiment of FIGS. 41-42.

FIG. 44 illustrates a top view of the embodiment of FIG. 43.

FIG. 45 illustrates a section view of the embodiment of FIG. 44, takenthrough line H-H of FIG. 44, with a second like structural bodymagnetically coupled.

FIG. 46 illustrates a detail view of cross section of FIG. 45.

FIG. 47 illustrates an alternate embodiment in which a captive magnet,with the polarity of the magnet of FIG. 46, is fully encapsulated.

FIG. 48 illustrates an alternate embodiment in which magnet polarity isoriented substantially perpendicular to the surface of the captivestructural body.

FIG. 49 illustrates an alternate embodiment in which a captive magnet,with the polarity of the magnet of FIG. 48, is fully encapsulated.

FIG. 50 illustrates an alternate embodiment in which the geometry ofeach magnetic node is based on a hexagon.

FIG. 51 illustrates an isometric view of a structural body based on thenodal architecture of FIG. 50.

FIG. 52 illustrates an exploded view of structural bodies incorporatingan alternate nodal surface geometry with sunken detent surfaces whichcan receive an optional intermediate detent ring to provide detentstops.

FIG. 53 illustrates a detail of the exploded view of FIG. 52.

FIG. 54 illustrates a collapsed view of the assembly of FIGS. 52-53,with the detent ring securely captured between magnetically coupledstructural bodies.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the present invention provide an architecture and methodfor creating a magnetic construction system including two or morestructural bodies each capturing one or more partially exposed,rotatable and self-aligning magnets. The unique structural aspects ofthe present invention are illustrated herein via various illustrativeembodiments, as will now be described in detail. The followingdescription is presented to enable one of ordinary skill in the art tomake and to use the invention, and is provided in the context of apatent application and its requirements.

Various modifications to the preferred embodiment and to the genericprinciples and features described herein will be readily apparent tothose skilled in the art. Thus, the present invention is not intended tobe limited to the embodiments shown but is to be accorded the widestscope consistent with the principles and features described herein.

FIG. 1 illustrates an exploded view of two structural body components100 a and 100 b coming together (e.g., to attach “temporarily” or“permanently”), capturing four spherical permanent dipole magnets 110within corresponding pockets 120. Each pocket 120 has an outward-facingopening with a restricted aperture 130 extending through respectivestructural body components 100 a and 100 b, allowing captive magnet 110to extend through wall thickness 140 of structural body components 100 aand 100 b while being rotatably retained within a cavity produced byfacing pockets 120, as further detailed in FIG. 5.

FIG. 2 illustrates structural body components 100 a and 100 b attachedto create structural body 100, rotatably capturing four permanent dipolemagnets 110, allowing each of the magnets 110 to freely rotate intopolar alignment with like magnets 110 in adjacent (nested or stacked)structural bodies. As a result, magnetic coupling of structural bodiesmay be achieved without regard to the polar orientation of magnets 110,and the contact or close proximity of respective magnets 110 maximizes amagnetic coupling force extending between contacting/close magnets 110.This magnetic coupling force joins one structural body to anotherstructural body as described herein. Among other advantages, thismagnetically self-aligning capability means that any part (e.g.,structural body 100) may be flipped over and magnetically coupled usingeither side, whereby any non-symmetrical parts do not require ‘left’ and‘right’ versions for symmetrical constructions.

Structural body portions such as 100 a and 100 b may be made from a widevariety of materials, such as plastic (including bio-plastic resins andplastic hybrids containing wood or other organic materials), wood,synthetic compounds, non-magnetic materials including non-ferrous metalsuch as aluminum, and the like, to name a few. In one embodiment of thepresent invention, structural body components 100 a and 100 b are madevia injection molding from a hard plastic such as polycarbonate, and areattached near edge (or perimeter) 200 of the respective body componentsvia ultrasonic welding, a process well understood by those skilled inthe art of injection molding and plastics processing. Other attachmentmethods such as fasteners, snap features, or adhesive could be used inlieu of, or in combination with the welding process.

FIG. 3 illustrates a top view of the structural body 100 of FIG. 2.

FIG. 4 illustrates a section view of the structural body 100 of FIG. 3,taken through line A-A in FIG. 3. Magnets 110 are rotatably capturedwithin pockets 120 and free to move, swivel, and orient about any axispassing through their respective geometric centers.

FIG. 5 illustrates a detail of the section view of FIG. 4. Clearancebetween each magnet 110 and pocket 120 allows a captured magnet 110 tofreely move, swivel, and orient to align its polarity coaxial andopposed to that of a magnet 110 in an adjacent structural body 100, asshown in FIG. 6 and FIG. 7. (In the figures, unless the context providesa different interpretation, “N” refers to a north magnetic pole and “S”refers to a south magnetic pole of a particular magnet 110.)

FIG. 6 illustrates the detail view of FIG. 5, with an additionalstructural body 100 approaching for magnetic coupling. As magneticfields of each magnet 110 overlap sufficiently to overcome the staticfriction between each magnet 110 and respective pocket 120, the magnets110 self-align to an orientation of coaxially aligned and opposedpolarity (e.g., a north pole of one magnet 110 touching or proximate asouth pole of another magnet 110 of a joining structural body 100). Asshown in FIG. 7, once structural bodies 100 have been magneticallycoupled, magnets 110 may contact at point 700, and a resulting sharedmagnetic polar axis 710 is oriented substantially perpendicular to asubstantially planar rim surface 720 of each structural body.

An upper limit for a diameter of aperture 130 is governed by the need tosecurely retain each magnet 110 and is related to a diameter ofspherical magnet 110; if the diameter of aperture 130 is too close tothe diameter of magnet 110, there will be a risk of magnet 110 becomingdislodged from its corresponding structural body 100. The specificproperties of the material chosen for structural body 100 also influencethis upper diameter limit, beyond which magnets could be dislodged fromthe structural body via material deflection or failure. The lower limitfor the diameter of aperture 130 is governed by the desire to allowcoupled magnets 110 to either contact or to come within close proximityto one another, maximizing magnetic coupling strength. Additionally,functional molding considerations such as minimum moldable wallthickness limit aperture 130 from being too small. Within these twobounds there is a range of acceptable diameter values suitable for anyparticular magnet diameter and suitable structural body material.

Further, for any specific diameter of aperture 130, the depth ofaperture 130 within structural body 100 should correspondingly preventmagnet 110 from protruding significantly beyond substantially planar rimsurface 720. As shown in FIG. 7, the coupling of two magnets therebyconstrains their respective structural bodies in close proximity toprovide stability to constructions. Conversely, aperture 130 should notretain each magnet 110 too deep within its corresponding structuralbody, thereby diminishing magnetic coupling strength by preventingmagnets 110 from magnetically coupling in close proximity. With aperture130 thus controlled, pocket 120 can be oversized, and of any shape, toaid in preventing foreign contaminants such as sand from interferingwith the rotation of magnets 110.

As illustrated in FIG. 8, magnet locations within structural body 100,and within other structural bodies according to the present inventiondisclosure, are driven by an underlying pattern 800 of efficientlynested, equal-sized equilateral triangles, wherein triangle vertexesrepresent possible locations for magnets 110 within the structuralbodies. The scale of a triangle side in pattern 800, which substantiallyequates to the diameter of a node (shown as radius 300), is preferablyan even multiple of the diameter of magnet 110, such that the diameterof a node approximates an integer value of stacked structural bodythicknesses. As a result, a node on edge (facilitated by structuralbodies such as those seen in FIGS. 21-24) may fit closely betweenstructural body layers. In one preferred embodiment, magnet 110 is aspherical neodymium magnet approximately 6.5 mm in diameter, providing adesirable amount of force for magnetic coupling, and node diameter isapproximately 32.5 mm, making it large enough to alleviate chokinghazard concerns.

The geometric form of structural bodies is also generally governed bypattern 800, whereby: a) any convex structural body radius 300 issubstantially equal to half the length of a side of a triangle withinpattern 800, and has a vertex as a center point; b) any concave radius310 is substantially equal to radius 300, and has a vertex as a centerpoint; c) magnets 110 are coincident with vertex locations of pattern800, and; d) magnetically coupled structural bodies share the sameunderlying pattern 800. As seen in FIG. 9, having these interactingcomplementary “convex” and “concave” surfaces allows multiple structuralbodies to closely nest with perimeter surfaces supporting one another,thereby distributing part weight or load over a larger number of magnets110 and increasing structural strength. Referring to FIGS. 10-20, astructural body form may therefore be a single node as in FIG. 10; alinear string of integer M number of nodes, M>1 (M=2-4 illustrated inFIGS. 11-13); or other forms derived from this 60-degree pattern 800 inwhich two or more nodes define an axis and one or more other nodes lieoff this axis by 60-degrees or 120-degrees, as seen in the examples ofFIGS. 14-20. The representative arrangements of nodes illustrated in thefigures are not exhaustive and other combinations and arrangements ofnodes that are consistent with pattern 800 are possible. Any part may beflipped over and magnetically coupled to any other part, as magnets willautomatically rotate into magnetic alignment. When two structural partsare coupled together into an assembly and associated correspondingmagnets have self-aligned, another structural body to be coupled to theassembly will have its magnets align with the magnet orientationestablished by the assembly. Any discrete solitaire structural body maylikewise be added into an assembly as the magnets are free to align tothe appropriate magnetic axes of corresponding magnets of the assembly.

FIGS. 21-24 illustrate structural body forms enabling construction onintersecting planes, thereby allowing the underlying structure ofpattern 800 of FIG. 8 to apply to multiple planes within a singlestructure. In FIGS. 21-22, structural body 2100 has a face 2110 orientedsubstantially perpendicular to substantially planar face 2120, allowingconstruction to accordingly shift to rotationally offset planes. FIG. 23illustrates a hinged structural body 2300, enabling magnetic node 2310to pivot out-of-plane with respect to magnetic node 2320 along an axis2330. FIG. 24 illustrates a structural body 2400 with each end node 2410attached to an elastomeric central member 2420, allowing end nodes 2410to be freely twisted or curved with respect to one another.

FIG. 25 shows a top view of the structural body of FIG. 10, with asection line C-C passing through the structural body where an undulatingsurface 2500 is at its highest point of amplitude on one side of thepart, corresponding with its lowest point of amplitude on the opposedside. As further illustrated in the section view detail of FIG. 26, thesurface 2500 surrounding magnet 110 has alternating protrusions 2610 andrecesses 2620 of a consistent amplitude 2630 repeated at regularintervals around a central axis 2640, creating a hermaphroditic detentfeature common between magnetic nodes of multiple structural bodies. Asa result, any surface 2500 is able to nest into any other surface 2500of another structural body, with respective magnets 110 pulling eachprotrusion 2610 into a corresponding recess 2620 to provide lateral androtational stability. Furthermore, when a rotational force is appliedbetween the structural bodies of magnetically coupled nodes, thestructural bodies may rotate relative to one another about any sharedmagnetic axis in an indexed or clicking manner without magneticallydecoupling. This rotation requires magnets 110 and correspondingstructural bodies to have a varying separation distance during rotation(as a protrusion moves from a depth of a recess toward an adjacentprotrusion and then back into the same or adjacent recess), against thecoupling force of magnets 110, in order for each protrusion 2610 of onestructural body to climb over each corresponding protrusion 2610 on themagnetically coupled structural body, after which the magnetic couplingforce pulls the structural bodies back together into the next stableposition of seated detents. Detent surface 2500 thereby serves twofunctions: 1) it provides rotational stability between magneticallycoupled nodes, and therefore structural stability to constructions, and;2) it ensures that the shared magnetic axis of coupled magnets 110 issubstantially perpendicular to the structural bodies, preventing orinhibiting structural bodies from sliding laterally about theirrespective coupled surfaces and thereby maintaining respective alignmentof structural bodies consistent with underlying pattern 800.

In at least one embodiment, undulating surface 2500 may be described asa radial sine wave, also known as a sinusoidal wave, with its smooth andrepetitive oscillation occurring radially about axis 2640 runningthrough the center of each node containing a magnet 110. The smoothtransitional nature of this form allows intentional rotation betweenlike surfaces 2500 of structural bodies while minimizing the risk ofunintentional magnetic decoupling. However, the exact geometry of detentsurface 2500 can take any one of numerous forms and similarly serve toprovide discreet rotational clicks and corresponding rotationalstability.

Amplitude 2630 between protrusions 2610 and recesses 2620 of surface2500, in wave or other form, governs a corresponding increase ordecrease in tactility of the detent clicking when structural bodies arerotated with respect to one another about the shared magnetic axis ofcoupled nodes. An increase in amplitude 2630 means respective rotationof structural bodies involves a greater transitional separation ofdetent surfaces 2500, requiring more force. However, a greaterseparation of magnets 110 reduces magnetic coupling force, and if thisamplitude is too large as compared to the magnetic coupling force,structural bodies are more apt to become inadvertently decoupled.Conversely, if the amplitude is too small, the detent surface 2500 mayprovide insufficient resistance against unwanted rotation between nodes,and may compromise the structural stability of constructed forms.Therefore, these two considerations govern a suitable range of valuesfor amplitude 2630. In at least one embodiment, said amplitude 2630 hasa value between 1 mm and 3 mm when system architecture is based on aneodymium magnet with a diameter of approximately 6.5 mm.

Further, detent surface 2500 is clocked in relation to underlyingpattern 800 such that any magnetically coupled structural body may beflipped 180 degrees over any line of pattern 800 and reseated into thecorresponding surface 2500 of the other structural body in ahermaphroditic (e.g., complementary) manner. This architecture requiresthat the mid-point of consistent amplitude 2630 is clocked to align withunderlying pattern 800. In at least one embodiment, a full cycle ofamplitude has a frequency, or pitch, such that a detent stop is providedevery 30 degrees of rotation about the axis of magnetically coupledparts. This rotational angle between detents may be greater or smaller,but preferably is an even divisor into 60 degrees, the basis of pattern800, so that magnetically coupled parts experience indexed stops capableof aligning with pattern 800.

FIG. 27 illustrates a top view of a second node surface geometry with aradially recessed surface 2700 around magnet 110. FIG. 28 illustrates across-section view of the structural body of FIG. 27, taken through lineD-D in FIG. 27. As shown, radial recessed surface 2700 about a centralaxis 2810 is sufficiently deep to clear all protrusions 2610 of anymagnetically coupled detent surface 2500, thereby allowing free rotationbetween respective nodes without indexed stops. Therefore, a structuralbody with a radial recessed surface 2700 on either or both sides of anynode, when placed between two, or against any, magnetically coupleddetent surfaces 2500, may transform the rotational behavior from onewith detent clicks to one which is freely rotatable. A sloped transitionsurface 2820 helps to center all protrusions 2610 of any magneticallycoupled detent surface 2500 within the radially recessed surface 2700,thereby providing lateral stability and ensuring respective magnets 110are coupled with a shared magnetic axis predominantly perpendicular tothe structural bodies, these structural bodies all conforming to pattern800.

FIG. 29 illustrates a wheel embodiment 2900 incorporating radialrecessed surface 2700 to enable free rotation about an axis 2910 ofmagnetic coupling. An additional recess feature 2920 in one or morelocations may provide a positive engagement feature for an optionalmotor drive coupling, wherein magnet 110 provides an attractive force tothe motor drive coupling, and recess feature 2920 prevents unwantedrelative rotation between the motor drive coupling and wheel 2900.

FIG. 30 illustrates an opposite side of the wheel embodiment of FIG. 29,incorporating undulating surface 2500.

FIG. 31 illustrates an example construction according to the system andmethod of the present invention. Wheel embodiments used in a singleassembly are shown having differing diameters (though someimplementations will include all wheels having the same diameter).

The disclosed invention readily lends itself to multiple variations.FIG. 32 illustrates an exploded view of an alternate embodiment, inwhich each magnet 110 may be rotatably captured by a first retainingring 3210 and a second retaining ring 3220 which together form magnetpocket 120 with aperture 130, as previously disclosed. In thisarchitecture, these retaining rings may incorporate surface 2500,thereby allowing a separate structural portion 3200 to be made of amaterial such as wood, which may be less suitable for the finetolerances required of surface 2500. FIG. 33 illustrates the assembledstate of the components of FIG. 32, with retaining rings 3210 and 3220capturing magnet 110 within structural portion 3200 to create astructural body 3300. FIG. 34 shows a top view of the embodiment of FIG.33, while FIG. 35 illustrates a cross section view of the embodiment ofFIG. 34, taken through line E-E of FIG. 34, showing magnet 110 rotatablyretained.

In a further variation shown in FIG. 36, each magnet 110 may berotatably retained within a separate face of a structural body 3600 by aretaining ring 3610 which exposes magnet 110 on only one face. FIG. 37illustrates the components of FIG. 36 assembled to create a structuralbody 3700, with surface 2500 integrated into each retaining ring 3610.FIG. 38 shows a top view of the structural body of FIG. 37, while FIG.39 illustrates a cross section of the same body as taken through lineF-F in FIG. 38. As shown, this architecture allows body 3700 to have anincreased thickness 3900 without a proportionate increase in diameterand associated cost of magnet 110. In keeping with the presentinvention, magnet 110 is free to rotate about any axis extending throughits center and may thereby self-align with other like magnets.

In an alternate embodiment, shown in FIG. 40, a spherical permanentdipole magnet 4010 is rotatably captured and fully encapsulated within aretaining pocket 4020, and surface 2500 is incorporated into theexternal nodal faces as according to the present invention disclosure.

In another embodiment, shown in FIG. 41, a structural body component4100 a may join with a structural body component 4100 b to pivotallycapture a magnet 4110 within a retaining pocket 4120. As illustrated inthe associated Detail G of FIG. 42, each magnet 4110 may have a polarity4200 substantially perpendicular to its geometric axis 4130, such thatthe polarity 4200 is constrained to a rotation 4210 about axis 4130,wherein polarity 4200 remains substantially parallel with the surface4230 of its captive structural body. FIG. 43 shows an assembled view ofthe components of FIG. 42, creating a structural body 4300 with detentsurfaces 2500 around each magnet 4110. FIG. 44 shows a top view ofstructural body 4300 of FIG. 43, and FIG. 45 illustrates a section viewof body 4300 taken though line H-H of FIG. 44, with a second structuralbody 4300 magnetically coupled. As shown in the detail view of FIG. 46,an exposed portion of magnet 4110 extends through thickness 4610 of eachrespective structural body to maximize magnetic coupling force. Theability of each magnet 4110 to pivot within its captive structural bodyallows magnets 4110 to self-align to an orientation of parallel andopposed magnetic poles, and also allows rotation between magneticallycoupled nodes.

FIG. 47 illustrates a partial view of an alternate embodiment with thesame magnet polarity as shown in FIG. 46, but with a magnet 4710 fullyencapsulated by material thickness 4720.

FIG. 48 illustrates a partial view of an alternate embodiment with amagnet 4810 with a magnetic polarity 4820 fixed or pivotally constrainedperpendicular to the substantially planar structural body surface. Inthis arrangement, polarity of structural bodies must be aligned formagnetic coupling, which may be useful for games or puzzles, whileexposed magnets 4810 maximize magnetic coupling force and each surface2500 provides rotational stops between magnetically coupled nodes,according to the present invention disclosure.

FIG. 49 illustrates a partial view of an alternate embodiment with thesame magnet polarity as shown in FIG. 48, but with a magnet 4910 fullyencapsulated by material thickness 4920.

FIG. 50 illustrates an alternate architectural embodiment based upon apolygonal (e.g., hexagonal) perimeter 5000 around each magnet 5110,rather than circular.

FIG. 51 illustrates an example structural body embodiment consistentwith the polygonal node architecture of FIG. 50. Outer perimeter 5100and locations of magnets 5110 conform to the underlying pattern 800previously disclosed, allowing perimeter 5100 to closely nest withperimeter sections of other structural bodies based on the samepolygonal architecture. Surface 2500 may optionally be incorporated intorespective structural bodies as shown, but is not required in someimplementations to achieve rotational stability since nested linear edgesegments may constrain rotation of respective structural bodies.

FIG. 52 illustrates an alternate embodiment. As shown in thecorresponding detail view of FIG. 53, the outer surface of eachstructural body, such as illustrated by examples 5210 and 5220, may besunken in a radial pattern 5320 around the axis of each respectivemagnet 5310, whereby: the geometry of the recess includes a furthersunken recess 5330, radial patterns 5320 and sunken recesses 5330 eachcorresponding with a substantially similar respective surface 5340 and5350 on each side of a second structural detent ring 5200, with detentring 5200 capable of nesting between any two magnetically coupledstructural bodies, as shown in FIG. 54. When in this enclosed orencapsulated position, detent ring 5200 thereby restricts structuralbodies to rotation only in an indexed, or clicking fashion, and when itis removed, free rotation of respective bodies is enabled. In anotherrelated embodiment, engaging detent topographies may be reversed,whereby feature 5330 is instead raised within sunken surface 5320, andcorresponding detent ring surface 5350 is sunken within surface 5340 toaccordingly engage in a detent manner.

As used herein, a permanent magnet is an article of manufacture or otherobject made from a magnetized material that creates its own persistentmagnetic field. As used herein, dipole, as in permanent dipole magnet,refers to two intrinsic poles of the permanent magnet: a north(magnetic) pole and an associated south (magnetic) pole with a magneticdipole moment pointing from the magnetic south pole to the magneticnorth pole. When referring to an embodiment of the present invention, amagnet refers to a permanent magnet with a pair of associated magneticpoles having an intrinsic magnetic dipole moment pointing from a southpole to a north pole.

The system and methods above have been described in general terms as anaid to understanding details of preferred embodiments of the presentinvention. In the description herein, numerous specific details areprovided, such as examples of components and/or methods, to provide athorough understanding of embodiments of the present invention. Somefeatures and benefits of the present invention are realized in suchmodes and are not required in every case. One skilled in the relevantart will recognize, however, that an embodiment of the invention can bepracticed without one or more of the specific details, or with otherapparatus, systems, assemblies, methods, components, materials, parts,and/or the like. In other instances, well-known structures, materials,or operations are not specifically shown or described in detail to avoidobscuring aspects of embodiments of the present invention.

Reference throughout this specification to “one embodiment”, “anembodiment”, or “a specific embodiment” means that a particular feature,structure, or characteristic described in connection with the embodimentis included in at least one embodiment of the present invention and notnecessarily in all embodiments. Thus, respective appearances of thephrases “in one embodiment”, “in an embodiment”, or “in a specificembodiment” in various places throughout this specification are notnecessarily referring to the same embodiment. Furthermore, theparticular features, structures, or characteristics of any specificembodiment of the present invention may be combined in any suitablemanner with one or more other embodiments. It is to be understood thatother variations and modifications of the embodiments of the presentinvention described and illustrated herein are possible in light of theteachings herein and are to be considered as part of the spirit andscope of the present invention.

It will also be appreciated that one or more of the elements depicted inthe drawings/figures can also be implemented in a more separated orintegrated manner, or even removed or rendered as inoperable in certaincases, as is useful in accordance with a particular application.

Additionally, any signal arrows in the drawings/Figures should beconsidered only as exemplary, and not limiting, unless otherwisespecifically noted. Furthermore, the term “or” as used herein isgenerally intended to mean “and/or” unless otherwise indicated.Combinations of components or steps will also be considered as beingnoted, where terminology is foreseen as rendering the ability toseparate or combine is unclear.

As used in the description herein and throughout the claims that follow,“a”, “an”, and “the” includes plural references unless the contextclearly dictates otherwise. Also, as used in the description herein andthroughout the claims that follow, the meaning of “in” includes “in” and“on” unless the context clearly dictates otherwise.

The foregoing description of illustrated embodiments of the presentinvention, including what is described in the Abstract, is not intendedto be exhaustive or to limit the invention to the precise formsdisclosed herein. While specific embodiments of, and examples for, theinvention are described herein for illustrative purposes only, variousequivalent modifications are possible within the spirit and scope of thepresent invention, as those skilled in the relevant art will recognizeand appreciate. As indicated, these modifications may be made to thepresent invention in light of the foregoing description of illustratedembodiments of the present invention and are to be included within thespirit and scope of the present invention.

Thus, while the present invention has been described herein withreference to particular embodiments thereof, a latitude of modification,various changes and substitutions are intended in the foregoingdisclosures, and it will be appreciated that in some instances somefeatures of embodiments of the invention will be employed without acorresponding use of other features without departing from the scope andspirit of the invention as set forth. Therefore, many modifications maybe made to adapt a particular situation or material to the essentialscope and spirit of the present invention. It is intended that theinvention not be limited to the particular terms used in followingclaims and/or to the particular embodiment disclosed as the best modecontemplated for carrying out this invention, but that the inventionwill include any and all embodiments and equivalents falling within thescope of the appended claims. Thus, the scope of the invention is to bedetermined solely by the appended claims.

What is claimed as new and desired to be protected by Letters Patent ofthe United States is:
 1. A magnetic construction apparatus, comprising:a planar body including a bottom surface, a top surface spaced apartfrom and parallel to said bottom surface, and a side surface extendingbetween said bottom surface and said top surface, said side surfacehaving a height and defining a closed loop perimeter around said bottomand top surfaces wherein said perimeter consists essentially of aplurality of alternating convex arc portions and concave portions, eachsaid convex arc portion having a substantially equal radius and acenterpoint disposed at a vertex of an equilateral triangular gridpattern and having a subtended arc angle with an integer multiple of 60degrees, said planar body further including a plurality of cavities,each cavity disposed at a particular one vertex of said equilateraltriangular grid pattern; and a magnetic element disposed within at leasttwo cavities of said plurality of cavities.
 2. The apparatus accordingto claim 1, wherein each said magnetic element is configured to rotatewithin its cavity about any axis extending through said magneticelement.
 3. The apparatus according to claim 2, wherein said magneticelement includes a spherical outer surface.
 4. The apparatus accordingto claim 1, wherein each said cavity defines a first aperture in saidbottom surface and a second aperture in said top surface, each saidaperture exposing a portion of said magnetic element retained withinsaid cavity.
 5. The apparatus according to claim 1, wherein a portion ofeach surface centered on each said cavity defines a mating surface andwherein each said mating surface includes a radial detent structureconsisting essentially of a periodic set of protrusions and recessescentered on any said cavity.
 6. The apparatus according to claim 5,wherein said set of protrusions and recesses occurs at a pitch frequencyincluding an integer multiple of 15 degrees.
 7. The apparatus accordingto claim 1, wherein a portion of each surface centered on each saidcavity defines a mating surface and wherein a particular one of saidmating surfaces includes a 360 degree radially recessed surface centeredon its associated cavity.
 8. The apparatus according to claim 1, whereina length of a triangle leg in said triangular grid pattern is an integermultiple of a length dimension between said bottom surface and said topsurface.
 9. A magnetic construction system, comprising: a plurality ofmagnetic connector bodies configured for mutual magnetic connection oneto another along mutually confronting, substantially planar faces ofsaid magnetic connector bodies, wherein each said magnetic connectorbody comprises: a planar body including a bottom face, a top face spacedapart from and parallel to said bottom face, and a side surfaceextending between said faces, said side surface having a height anddefining a closed loop perimeter around said faces, wherein saidperimeter consists essentially of a plurality of alternating convex arcportions and concave portions, each said convex arc portion having asubstantially equal radius and a centerpoint disposed at a vertex of anequilateral triangular grid pattern and having a subtended arc anglewith an integer multiple of 60 degrees, said planar body furtherincluding a plurality of cavities, each cavity disposed at a particularone vertex of said equilateral triangular grid pattern; and a magneticelement disposed within at least two cavities of said plurality ofcavities.
 10. The system according to claim 9, wherein each saidmagnetic element is configured to rotate within its cavity about anyaxis extending through said magnetic element.
 11. The system accordingto claim 10, wherein said magnetic element includes a spherical outersurface.
 12. The system according to claim 9, wherein each said cavitydefines a first aperture in said bottom surface and a second aperture insaid top surface, each said aperture exposing a portion of said magneticelement retained within said cavity.
 13. The system according to claim9, wherein a portion of each surface centered on each said cavitydefines a mating surface and wherein each said mating surface includes aradial detent structure consisting essentially of a periodic set ofprotrusions and recesses centered on any said cavity.
 14. The systemaccording to claim 13, wherein said set of protrusions and recessesoccurs at a pitch frequency including an integer multiple of 15 degrees.15. The system according to claim 9, wherein a portion of each surfacecentered on each said cavity defines a mating surface and wherein aparticular one of said mating surfaces includes a 360 degree radiallyrecessed surface centered on its associated cavity.
 16. The systemaccording to claim 9, wherein a length of a triangle leg in saidtriangular grid pattern is an integer multiple of a length dimensionbetween said bottom surface and said top surface.
 17. The systemaccording to claim 9 including a first particular magnetic connectorbody having a first configuration and a second particular magneticconnector body having a second configuration different from said firstconfiguration, wherein said configurations include a number of magneticelement containing cavities and include a spatial layout of said numberof magnetic element containing cavities.
 18. A magnetic constructionsystem, comprising: a plurality of magnetic connector bodies configuredfor mutual magnetic coupling one to another using mutually confronting,substantially planar faces of said magnetic connector bodies, whereineach said magnetic connector body comprises: a planar body including abottom face, a top face spaced apart from and parallel to said bottomface, and a side surface extending between said faces, said side surfacehaving a height and defining a closed loop perimeter around said faces,wherein said perimeter consists essentially of a plurality ofalternating convex arc portions and concave portions, each said convexarc portion having a substantially equal radius and a centerpointdisposed at a vertex of an equilateral triangular grid pattern andhaving a subtended arc angle with an integer multiple of 60 degrees,said planar body further including a plurality of cavities disposedinside said perimeter, each said cavity disposed at a particular onevertex of said equilateral triangular grid pattern; and a magneticelement disposed within at least two cavities of said plurality ofcavities; and wherein a first set of said plurality of magneticconnector bodies include a first number N of said plurality of cavitiesdisposed within said perimeter, N>1; and wherein a second set of saidplurality of magnetic connector bodies include a second number M of saidplurality of cavities disposed within said perimeter, M>1 and M≠N. 19.The system according to claim 18 wherein each said magnetic elementincludes a pole orientation direction from a south pole to a north pole,wherein a combination of each said cavity and said disposed magneticelement is cooperatively configured for permitting a rotation of saiddisposed magnetic within its cavity about any axis extending throughsaid disposed magnetic element, and wherein said rotation changes saidpole orientation direction of said disposed magnet.